Grid assembly for a plate-shaped battery electrode of an electrochemical accumulator battery

ABSTRACT

The invention relates to a grid arrangement for a plate-shaped battery electrode of an electrochemical accumulator having a frame and a grid arranged thereon, wherein the frame comprises at least one upper frame element having a connecting lug of the battery electrode disposed on its side facing away from the grid, and wherein the grid is at least formed by horizontal bars, which are bars extending substantially horizontally, and vertical bars, which are bars extending substantially vertically, wherein at least some of the vertical bars are arranged at different angles to one another in the shape of a fan. The invention further relates to an accumulator.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and is a continuation of U.S.Nonprovisional application Ser. No. 15/027,592 entitled GRID ASSEMBLYFOR A PLATE-SHAPED BATTERY ELECTRODE OF AN ELECTROCHEMICAL ACCUMULATORBATTERY filed Apr. 6, 2016, which is a national stage filing ofInternational Application No. PCT/EP2014/071556 entitled GRIDARRANGEMENT FOR A PLATE-SHAPED BATTERY ELECTRODE OF AN ELECTROCHEMICALACCUMULATOR AND ACCUMULATOR filed Oct. 8, 2014, which claims priority toGerman patent application DE 102013111109.2 filed Oct. 8, 2013, thecontents of each of which are hereby incorporated by reference in theirentirety.

FIELD OF THE INVENTION

The invention relates to a grid arrangement for a plate-shaped batteryelectrode of an electrochemical accumulator in accordance with thepreamble of claim 1. The invention further relates to an accumulator inaccordance with claim 7.

BACKGROUND

Generally speaking, the invention relates to the field ofelectrochemical accumulators having plate-shaped battery electrodes,also known as electrode plates. Such accumulators are particularlymanufactured as lead-acid batteries. Grid arrangements for such batteryelectrodes are described for example in DE 10 2008 029 386 A1 and WO01/04977 A1. Such grid arrangements are usually made of lead. Due torising raw material prices and with the objective of reducing the weightof electrochemical accumulators, minimizing the amount of lead used isdesirable.

The invention is thus based on the task of specifying an optimized gridarrangement with which the amount of lead needed can be reduced withoutany impairing of performance.

SUMMARY

This task is solved in accordance with claim 1 by a grid arrangement fora plate-shaped battery electrode of an electrochemical accumulatorhaving a frame and a grid arranged thereon, wherein the frame comprisesat least one upper frame element having a connecting lug of the batteryelectrode disposed on its side facing away from the grid, and whereinthe grid is at least formed by horizontal bars, which are bars extendingsubstantially horizontally, and vertical bars, which are bars extendingsubstantially vertically, wherein at least some of the vertical bars arearranged at different angles to one another in the shape of a fan, andhaving at least one, some or all of the following a), b), c), d)features:

a) a straight line which runs through the center of gravity of the gridarrangement and is a parallel to the central axis of the vertical barhaving the shortest distance to the grid arrangement's center ofgravity, passes the connecting lug at a distance of less than 15%, inparticular less than 10%, of the connecting lug width, or intersects theconnecting lug,

b) a straight line which runs through the center of gravity of the gridarrangement and is a parallel to the central axis of the vertical barhaving the shortest distance to the grid arrangement's center ofgravity, intersecting the upper frame element at a point which is lessthan 15%, particularly less than 10%, of the length of the upper frameelement away from a vertical central axis of the connecting lug,

c) the sum of all the angles of those vertical bars which intersect boththe upper as well as the lower frame element of the grid arrangement, orat least would intersect in mathematical extension, is greater than 7°,wherein the angles are defined in terms of an axis extending exactlyvertically,

d) the sum of the angles of the outermost left and outermost rightvertical bar intersecting both the upper as well as the lower frameelement of the grid arrangement, or at least would intersect inmathematical extension, is greater than 7°, wherein the angles aredefined in terms of an axis extending exactly vertically.

In simplified terms, the grid arrangement according to the inventiondistinguishes itself from known grid arrangements by the arrangement ofthe vertical bars as a whole being canted or tilted toward theconnecting lug. This enables on the one hand the desired materialsavings in raw lead material, along with the accompanying weightsavings, and additionally, despite economizing on the raw material, evenfurther improved electrical conductivity. The inventive grid arrangementthus enables the providing of an accumulator which weighs less thanknown accumulators and yet exhibits better electrical performance data.

The cited modified spatial orientation of the vertical bars can berendered pursuant to one, multiple or all of the a), b), c), d) featuresof claim 1.

As per feature a) and b), a straight line is thereby defined throughwhich the grid arrangement's center of gravity runs. The gridarrangement's center of gravity is to be understood, as commonlyaccepted in physics, as the center of mass of the grid arrangement,including the connecting lug. The center of mass of a body is themass-weighted average of its mass point positions. The grid arrangementis usually made of relatively homogeneous lead material such that thecenter of mass then also corresponds to the geometrical center ofgravity. The cited straight line running through the grid arrangement'scenter of gravity is moreover a parallel to the central axis of thevertical bar at the shortest distance from the grid arrangement's centerof gravity. Thus, the vertical bar situated closest to the center ofgravity needs to be determined; the cited straight line is a parallel toits central axis. The central axis is the longitudinal axis of thevertical bar, so to speak, that which runs dead center along thevertical bar in the longitudinal direction, thus substantiallyvertically. The central axis can inasmuch also be referred to asbisecting the vertical bar.

According to feature a), the straight line can pass the connecting lugat a certain distance or intersect it. If the straight line passes theconnecting lug, it has no point of intersection with the connecting lug.According to feature b), the defined straight line similarly intersectsthe upper frame element at a specific point defined in relation to thevertical central axis of the connecting lug as previously clarified. Tobe understood as the vertical central axis in this case is an axisrunning exactly vertically at the dead center of the connecting lug.

Insofar as the usage of terms such as horizontally, vertically, above,below and/or horizontal or vertical, these terms refers to the mountingorientation of the battery electrode in an electrochemical accumulatorwhen in normal position for specification-compliant use. As a rule, thespecification-compliant normal position of the accumulator is with thebottom of the accumulator being in a horizontal position.

Where angles are specified in degrees (e.g. 7°), the specificationsrefer to an overall circular dimension of 360°.

According to one advantageous further development of the invention, thevertical bars arranged in the manner of a fan exhibit an angulardifference of less than 5° between adjacent vertical bars. This allowsfurther optimizing of the grid arrangement in terms of electricalperformance as well as the material quantity and thus the weight.

According to one advantageous further development of the invention, theconnecting lug is arranged asymmetrically on the upper frame element.The connecting lug has a first vertical side, disposed on the side ofthe longer leg of the upper frame element, whereby the straight lineaccording to feature a) of claim 1 passes or intersects the connectinglug at its first vertical side and/or the point at which the straightline according to feature b) of claim 1 intersects the upper frameelement is situated in the region of the upper frame element's longerleg. This thereby further optimizes the electrical conductivity as wellas the need for material and the weight of the grid arrangement. Thecited straight line is then situated on the side of the connecting lug'sinner lug corner as it were; i.e. the corner facing the longer leg ofthe upper frame element.

According to one advantageous further development of the invention, thegrid arrangement is a stamped lead grid. According to one advantageousfurther development of the invention, the grid arrangement is designedas a positive grid arrangement for a positive battery electrode.

The grid arrangement at least comprises the upper frame element. Thegrid arrangement can additionally comprise a lower frame element, a leftas well as a right frame element, wherein the upper frame element isconnected to the lower frame element by means of the left and right sideframe elements. The grid is thereby arranged with the frame. Doing soprovides a grid arrangement of increased robustness including in itslower regions.

The task cited at the outset is additionally solved pursuant to claim 7by an accumulator having a plurality of plate-shaped battery electrodesarranged into one or more electrode plate packs, wherein one, multipleor all of the battery electrodes comprise a grid arrangement inaccordance with one of the preceding claims.

These and other features and advantages of devices, systems, and methodsaccording to this invention are described in, or are apparent from, thefollowing detailed descriptions of various examples of embodiments.

BRIEF DESCRIPTION OF DRAWINGS

Various examples of embodiments of the systems, devices, and methodsaccording to this invention will be described in detail, with referenceto the following figures, wherein:

FIG. 1 is a semi-exploded view of an accumulator and its structuralelements;

FIG. 2 is a grid arrangement;

FIG. 3 is a grid arrangement provided with an active mass;

FIG. 4 is the encasing of a grid arrangement provided with an activemass within a separator;

FIG. 5 is a top view of the grid arrangement according to the invention;and

FIG. 6 is a top view of a further inventive grid arrangement.

The figures make use of the same reference numerals for equivalentelements.

It should be understood that the drawings are not necessarily to scale.In certain instances, details that are not necessary to theunderstanding of the invention or render other details difficult toperceive may have been omitted. It should be understood, of course, thatthe invention is not necessarily limited to the particular embodimentsillustrated herein.

DETAILED DESCRIPTION

FIG. 1 illustrates an example basic design of an accumulator 100according to the invention. The accumulator 100 can in particular bedesigned as a lead-acid battery having liquid electrolyte, for examplein the form of sulfuric acid. The accumulator 100 has a housing 110 inwhich or more or more plate packs 107 are arranged. The accumulator 100has a fixed number of plate packs 107 based on its number of cells. Theplate packs 107 are respectively arranged in individual holding chambersof the housing 110 separated from one another by partitions. The platepacks 107 are connected together into a series connection within thehousing 110 by internal connecting elements not depicted in FIG. 1. Thepositive plates at the one end of the plate pack and the negative platesat the other end of the plate pack are electrically connected torespective external terminals 108, 109 located in a cover part 111 ofthe accumulator housing 110. The electrical energy of the accumulator100 is supplied to electrical loads through terminals 108, 109.

The plate packs 107 comprise respectively alternating positive andnegative electrode plates. The negative electrode plates are depicted asnegative plate group 115, the positive electrode plates as positiveplate group 114. FIG. 1 includes a depiction of individual electrodeplates for illustrative purposes; i.e. a negative electrode plate 105comprising a negative flat lead grid 102 and a positive electrode plate104 comprising a positive flat lead grid 101. The positive electrodeplate 104 and the negative electrode plate 105 depicted in FIG. 1already exhibit a pasting with active mass, same covering the individualgrid bars and cutouts. The positive and/or negative lead gridcomprise(s) a plurality of grid bars and a plurality of window-likecutouts formed between the grid bars. The positive and/or negative leadgrid 101, 102 can be produced for example in a stamping process or bymeans of other methods such as casting and/or rolling.

The positive electrode plate 104 is additionally separated from thenegative electrode plate 105 by a separator material 106. The separatormaterial 106 can in particular be formed into the shape of a pouch toaccommodate the positive electrode plate 104 and separate it fromadjacent electrode plates.

The positive electrode plates 104 each comprise a respective connectinglug 103 by means of which the electrode plates in the positive plategroup 114 are connected together into a parallel connection. Thenegative electrode plates 105 each comprise a respective connecting lug103 by means of which the electrode plates in the negative plate group115 are connected together into a parallel connection. The connectioncan be made by a connector 112 soldered or welded onto the connectinglugs 103 as is recognizable in FIG. 1.

The accumulator 100 according to FIG. 1 can in particular comprise oneor more inventive electrode plates, e.g. in the form of positiveelectrode plates 104.

FIG. 2 shows an example of a positive lead grid 101 in a top plan view.It can be seen that the lead grid 101 has a plurality of grid bars 114,between which is a plurality of window-like cutouts 113. To make iteasier to handle and for purposes of mechanical stability as well asimproved electrical properties, the outer edge of the lead grid 101 canexhibit one, some or all of the following cited frame sections: upperframe section 115, left side frame section 119, lower frame section 117,right side frame section 118.

FIG. 3 shows the lead grid 101 from FIG. 2 after having been at leastpartly covered with active mass, which is usually applied in paste form.This process is also known as pasting. FIG. 4 shows the lead grid 103 ofFIG. 3 having been provided with the active mass being inserted into awrapper-like separator 106.

FIG. 5 shows a grid arrangement 101 formed according to the invention,again comprising a frame having an upper frame element 120, a lowerframe element 117, a right side frame element 118 and a left side frameelement 119. The grid 113 is situated within the area enclosed by theabove-cited frame elements. As can be seen, the connecting lug 103disposed on the upper frame element 120 is arranged asymmetrically onthe upper frame element 120, somewhat to the right of the gridarrangement center. A vertical central axis A running exactly verticalintersects the center of the connecting lug 103. The vertical centralaxis A thereby also serves as a vertical reference axis.

Further reference numerals are provided in FIG. 5 to specify the grid113 in greater detail. The grid 113 comprises a plurality of horizontalbars; of these, horizontal bars 21 to 25 have been provided withreference numerals for illustrative purposes. The horizontal bars extendsubstantially horizontally. Vertical bars intersect or cross or aretangent to the horizontal bars. Of the vertical bars, vertical bars 9 to20 have been provided with reference numerals for illustrative purposes.The vertical bars do not run exactly vertically but rather at differentangles to each other in the shape of a fan, whereby they radiateoutwardly from the upper frame element 120. The vertical bars identifiedby reference numerals 9 to 20 intersect both the upper frame element aswell as, at least in a mathematical extension, the lower frame element117. Further vertical bars arranged to the left and right thereof, whichare not provided with reference numerals, do not intersect the lowerframe element 117, not even in a mathematical extension.

It is provided with the grid arrangement according to the invention forthe sum of all the angles of the vertical bars 9 to 20; i.e. thevertical bars intersecting both the upper as well as the lower frameelement of the grid arrangement, or at least intersecting inmathematical extension, to be greater than 7°. The angles are definedhere with respect to the vertical reference axis A. This results in thesum of all the angles being approximately equivalent to the intersectingangle of central axis M with vertical reference axis A. In other words,the angle of inclination to the vertical reference axis A yielded by thesummation is a value greater than 7°.

In corresponding manner, the inventive grid arrangement also exhibits avalue greater than 7°, again relative to the vertically extendingreference axis A, with respect to the sum of the angles of the outermostleft vertical bar 9 and the outermost right vertical bar 20 whichintersect both the upper and well as the lower frame element of the gridarrangement, or at least would intersect in mathematical extension.

The connecting lug 103 has a first vertical side 2 arranged on the sideof the longer leg 3 of the upper frame element 120. An opposite secondvertical side 4 is arranged on the side of the shorter leg 5 of theupper frame element 120. The legs 3, 5 are formed to the respective leftand right of the connecting lug 103.

The center of gravity S is plotted in the grid arrangement according toFIG. 5. Vertical bar 14 is the vertical bar situated closest the centerof gravity S; i.e. the vertical bar having the least distance from thecenter of gravity S. The central axis M of vertical bar 14 is alsoplotted in FIG. 5. A parallel to central axis M running through thecenter of gravity S is further plotted as straight line G. Said straightline G passes the connecting lug 103 on the first vertical side 2 at adistance D. In the grid arrangement according to the invention, thestraight line G can also intersect the connecting lug 103, particularlyin the area of the first vertical side 2. The intersecting point canalso be situated at other locations on the connecting lug 103, rangingto the second vertical side 4 of the connecting lug 103 opposite fromthe first vertical side 2.

It can further be provided in the inventive grid arrangement for a point1 at which the straight line G intersects the upper frame element 120 tobe situated at a distance less than 15%, in particular less than 10% ofthe length L of the upper frame element 120 from the vertical centralaxis A of the connecting lug 103. The length L of the upper frameelement 120, which also concurrently corresponds to the width of thegrid arrangement 101, is plotted in FIG. 5. The width B of theconnecting lug 103 is likewise plotted.

FIG. 6 shows a further inventive grid arrangement 101 having a narrowerstructure than the embodiment according to FIG. 5. The length L of theupper frame element is thus shorter than in the embodiment according toFIG. 5. Because of the shorter total width, the grid arrangement 101according to FIG. 6 has fewer vertical bars. Among the vertical bars,only vertical bars 9, 10, 11, 14, 17, 18, 19 and 20 intersect the upperframe element and, at least in mathematical extension, also the lowerframe element 117. Of this subset of vertical bars, vertical bar 9 isagain the outermost left vertical bar and vertical bar 20 the outermostright vertical bar. Further vertical bars not provided with referencenumerals are arranged to the left and right of this subset of verticalbars and also do not intersect the lower frame element 117 in extension.In the embodiment according to FIG. 6, vertical bar 14 is again thevertical bar situated closest to the center of gravity S of the gridarrangement 101.

The reference numerals of FIG. 6 otherwise correspond to those of FIG.5.

To aid in identification, FIG. 6 also separately plots, to the right ofthe grid arrangement, the arrangement of the center of gravity S,central axis M and straight line G as well as the distance D from theconnecting lug 103 without the grid bars. The course of straight line Gin the left part of FIG. 6 is somewhat hard to distinguish due to partof it running along the edge of vertical bar 14.

The embodiments according to FIGS. 5 and 6 document the universalapplicability of the present invention.

As utilized herein, the terms “approximately,” “about,” “substantially”,and similar terms are intended to have a broad meaning in harmony withthe common and accepted usage by those of ordinary skill in the art towhich the subject matter of this disclosure pertains. It should beunderstood by those of skill in the art who review this disclosure thatthese terms are intended to allow a description of certain featuresdescribed and claimed without restricting the scope of these features tothe precise numerical ranges provided. Accordingly, these terms shouldbe interpreted as indicating that insubstantial or inconsequentialmodifications or alterations of the subject matter described and claimedare considered to be within the scope of the invention as recited in theappended claims.

It should be noted that references to relative positions (e.g., “top”and “bottom”) in this description are merely used to identify variouselements as are oriented in the Figures. It should be recognized thatthe orientation of particular components may vary greatly depending onthe application in which they are used.

For the purpose of this disclosure, the term “coupled” means the joiningof two members directly or indirectly to one another. Such joining maybe stationary in nature or moveable in nature. Such joining may beachieved with the two members or the two members and any additionalintermediate members being integrally formed as a single unitary bodywith one another or with the two members or the two members and anyadditional intermediate members being attached to one another. Suchjoining may be permanent in nature or may be removable or releasable innature.

It is also important to note that the construction and arrangement ofthe system, methods, and devices as shown in the various examples ofembodiments is illustrative only. Although only a few embodiments havebeen described in detail in this disclosure, those skilled in the artwho review this disclosure will readily appreciate that manymodifications are possible (e.g., variations in sizes, dimensions,structures, shapes and proportions of the various elements, values ofparameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter recited. For example,elements shown as integrally formed may be constructed of multiple partsor elements show as multiple parts may be integrally formed, theoperation of the interfaces may be reversed or otherwise varied, thelength or width of the structures and/or members or connector or otherelements of the system may be varied, the nature or number of adjustmentpositions provided between the elements may be varied (e.g. byvariations in the number of engagement slots or size of the engagementslots or type of engagement). The order or sequence of any process ormethod steps may be varied or re-sequenced according to alternativeembodiments. Other substitutions, modifications, changes and omissionsmay be made in the design, operating conditions and arrangement of thevarious examples of embodiments without departing from the spirit orscope of the present inventions.

While this invention has been described in conjunction with the examplesof embodiments outlined above, various alternatives, modifications,variations, improvements and/or substantial equivalents, whether knownor that are or may be presently foreseen, may become apparent to thosehaving at least ordinary skill in the art. Accordingly, the examples ofembodiments of the invention, as set forth above, are intended to beillustrative, not limiting. Various changes may be made withoutdeparting from the spirit or scope of the invention. Therefore, theinvention is intended to embrace all known or earlier developedalternatives, modifications, variations, improvements and/or substantialequivalents.

The technical effects and technical problems in the specification areexemplary and are not limiting. It should be noted that the embodimentsdescribed in the specification may have other technical effects and cansolve other technical problems.

1.-7. (canceled)
 8. An electrochemical accumulator, wherein theaccumulator comprises: a frame including an upper element having aconnecting lug for a battery electrode, wherein the connecting lug isoffset from a center of gravity of the accumulator; a grid arranged onthe frame, wherein the grid includes: a plurality of substantiallyhorizontal bars; and a plurality of substantially vertical bars, whereineach of the substantially vertical bars is positioned at an angledirected toward the connecting lug, and wherein one of the plurality ofthe vertical bars has a central axis, wherein a sum of all of the anglesof the plurality of vertical bars is equivalent to an intersecting angleof the central axis with a vertical reference axis.
 9. Theelectrochemical accumulator of claim 8, wherein the intersecting angleof the central axis with the vertical reference axis is greater than 7°.10. The electrochemical accumulator of claim 8, wherein the connectinglug is arranged on a longer leg of the upper element of the frame. 11.The electrochemical accumulator of claim 8, wherein a straight linepassing through the center of gravity and parallel to the central axisis offset from the central axis by a first distance.
 12. Theelectrochemical accumulator of claim 11, wherein the straight linepasses the connecting lug and the first distance is less than 15% of awidth of the connecting lug.
 13. The electrochemical accumulator ofclaim 12, wherein the first distance is less than 10% of the width ofthe connecting lug.
 14. The electrochemical accumulator of claim 11,wherein the straight line intersects the upper element of the frame andthe first distance is less than 15% of the length of the upper elementaway from a vertical central axis of the connecting lug.
 15. Theelectrochemical accumulator of claim 14, wherein the straight lineintersects the upper element of the frame and the first distance is lessthan 10% of the length of the upper element away from a vertical centralaxis of the connecting lug.
 16. The electrochemical accumulator of claim8, wherein an angle of one vertical bar relative to an adjacent verticalbar is less than 5°.
 17. An electrochemical accumulator, wherein theaccumulator comprises: a frame including at least an upper portionhaving a connecting lug and opposing side portions, wherein theconnecting lug is offset on the upper portion such that a first side ofthe upper portion is longer than a second side of the upper portion; anda grid arranged on the frame, wherein the grid includes a plurality ofsubstantially horizontal bars and a plurality of substantially verticalbars, wherein the vertical bars extend radially from the connecting lug,and wherein a portion of the horizontal bars adjacent the opposing sideportions of the frame are offset relative to another portion of thehorizontal bars in a central portion of the grid.
 18. Theelectrochemical accumulator of claim 17, wherein the intersecting angleof the central axis with the vertical reference axis is greater than 7°.19. The electrochemical accumulator of claim 17, wherein the connectinglug is arranged on the first side of the upper portion of the frame. 20.The electrochemical accumulator of claim 17, wherein a straight linepassing through the center of gravity and parallel to the central axisis offset from the central axis by a first distance.
 21. Theelectrochemical accumulator of claim 20, wherein the straight linepasses the connecting lug and the first distance is less than 15% of awidth of the connecting lug.
 22. The electrochemical accumulator ofclaim 21, wherein the first distance is less than 10% of the width ofthe connecting lug.
 23. The electrochemical accumulator of claim 20,wherein the straight line intersects an upper frame element and thefirst distance is less than 15% of the length of the upper frame elementaway from a vertical central axis of the connecting lug.
 24. Theelectrochemical accumulator of claim 21, wherein the straight lineintersects an upper frame element and the first distance is less than10% of the length of the upper frame element away from a verticalcentral axis of the connecting lug.
 25. The electrochemical accumulatorof claim 17, wherein an angle of one vertical bar relative to anadjacent vertical bar is less than 5°.
 26. The electrochemicalaccumulator of claim 17, wherein at least a portion of the substantiallyhorizontal bars is positioned at an angle relative to an adjacenthorizontal bar.
 27. The electrochemical accumulator of claim 26, whereinthe portion of substantially horizontal bars positioned at an angle issubstantially perpendicular to an adjacent substantially vertical bar.